BARNSTEAD|THERMOLYNE CORPORATION

Type F1500
Muffle Furnace
OPERATION MANUAL
AND PARTS LIST
SERIES 327

Model # Voltage Control

FD1535M 120 Single Set Point
FD1538M 208 Single Set Point
FD1530M 240 Single Set Point
FD1530M-26 240 Single Point Set
FD1534M 100 Single Set Point
FD1545M 120 Programmable (2 Ramp & 2 Dwell)
FD1548M 208 Programmable (2 Ramp & 2 Dwell)
FD1540M 240 Programmable (2 Ramp & 2 Dwell)
FD1540M-26 240 Programmable (2 Ramp & 2 Dwell)
FD1544M 100 Programmable (2 Ramp & 2 Dwell)

LT327X3 • 12/15/97
1
Table of Contents

General Information ........................................................................................................................................... 3

Alert Signals ..................................................................................................................................................... 3
Safety Information ............................................................................................................................................ 3
Important Information ....................................................................................................................................... 3
Warnings .......................................................................................................................................................... 3
Introduction ...................................................................................................................................................... 4
Intended Use .................................................................................................................................................. 4
Principles of Operation ................................................................................................................................... 5
General Specifications ....................................................................................................................................... 6
Unpacking .......................................................................................................................................................... 7
Installation .......................................................................................................................................................... 8
Single Setpoint Temperature Control (Automatic) Operation ............................................................................. 9
Operation of 2 Ramp & 2 Dwell Programmable Models .................................................................................. 12
Operating the Controller ................................................................................................................................... 16
Implementing Programs ................................................................................................................................... 20
Furnace Loading .............................................................................................................................................. 21
Preventive Maintenance ................................................................................................................................... 22
Troubleshooting ............................................................................................................................................... 23
Maintenance and Servicing .............................................................................................................................. 25
Figures ............................................................................................................................................................. 29
Replacement Parts List .................................................................................................................................... 31
Wiring Diagram ................................................................................................................................................ 32
Ordering Procedures ........................................................................................................................................ 33
Material Safety Data Sheet .............................................................................................................................. 34
Warning ............................................................................................................................................................ 38
Warranty ........................................................................................................................................................... 39

2
 General Information

Alert Signals Safety Information

Your Thermolyne Muffle Furnace has been
Warning designed with function, reliability, and safety in
Warnings alert you to a possibility mind. It is the user’s responsibility to install it in
of personal injury. conformance with local electrical codes. For
safe operation, please pay attention to the alert
boxes throughout the manual.
Caution
Cautions alert you to a possibility
of damage to the equipment.
Important Information
This manual contains important operating and
Note safety information. The user must carefully
Notes alert you to pertinent facts read and understand the contents of this
and conditions. manual prior to the use of this equipment.

Hot Surface
Hot surfaces alert you to a Warnings
possibility of personal injury if you
come in contact with a surface
during use or for a period of time
after use. To avoid electric shock, this furnace must:

1. Use a properly grounded electrical

outlet of correct voltage and current
handling capacity.

2. Disconnect from power supply before

servicing.

3. Have the door switch operating

properly.

3
GENERAL INFORMATION

To avoid personal injury:

1. Do not use in the presence of flam-
mable or combustible materials ; fire or
explosion may result. This device con-
tains components which may ignite such
material.

2. Caution: Hot Surface - Avoid Contact.

To avoid burns, do not touch the interior
or exterior surfaces of the furnace during
use or for a period of time after use.

3. Refer servicing to qualified personnel.

Introduction

Intended Use
The type 1500 furnaces are general laboratory
and heat treating furnaces. These furnaces are
intended for applications requiring temperatures
from 212°F (100°C) to 2192°F (1200°C). For
maximum element life, it is recommended to
operate the furnace at temperatures from 212°F
(100°C) to 1950°F (1066°C) for continuous use or
temperatures from 1950°F (1066°C) to 2192°F
(1200°C) for intermittent use. Continuous use is
operating the furnace for more than 3 hours and
intermittent use is operating the furnace for less
than 3 hours.

The unit consists of 1) a heating chamber, 2) a

digital temperature control and, 3) a power switch.
See Figure 1, page 29 for overall shape and
general features of the unit.

4
 GENERAL INFORMATION

Principles of Operation
The furnace chamber is heated by four electric
resistance heaters which are embedded in a
refractory material. The chamber is insulated
with a ceramic fiber insulation. For safety, a
door switch is incorporated to remove power
from heating elements when door is opened.
The furnace chamber is supported by the
control section which also houses the electrical
connections.

Two types of temperature controls are used:

1) Single Set Point (Automatic) This is
an electronic control which enables
the user to bring the furnace up to a
preset point and hold that tempera-
ture.

2) Programmable (2 ramp and 2 dwell)

This control is designed to control a
programmed temperature profile. The
profile is in the format of ramps and
dwell segments. The first ramp, RAMP
1, starts at the initial measured Fur-
nace temperature. This ramp is posi-
tive going at a programmed rate until
the programmed level is reached. The
setpoint will stay at this level for a
period determined by the setting of
DWELL 1. When the second ramp
reaches the second programmed
level, the setpoint stays at that level
for the duration of the segment. De-
pending upon the model ordered,
additional ramp and dwell segments
may be added.

5
General Specifications for
Furnaces
FD1540M & (26)° FD1544M FD1545M FD1548M
Model #
FD1530M & (26)° FD1534M FD1535M FD1538M

4 4 4 4
Width
(10) (10) (10) (10)

3-3/4 3-3/4 3-3/4 3-3/4

Chamber Height
(9.5) (9.5) (9.5) (9.5)

9 9 9 9
Depth
(22.9) (22.9) (22.9) (22.9)
Dimensions
in. (cm)
11 11 11 11
Width
(28) (28) (28) (28)

16-1/2 16-1/2 16-1/2 16-1/2

Overall Height
(42) (42) (42) (42)

18 18 18 18
Depth
(46) (46) (46) (46)

Lbs. 42 42 42 42
Weight
Kg. (19) (19) (19) (19)

Volts 240 100 120 208

Amps 9.3 20.7 18.6 10.7

Watts 2230 2070 2230 2225

Electrical Ratings

Freq. 50/60 50/60 50/60 50/60

Phase 1 1 1 1

Cont. 100°C - 1066°C 100°C - 1066°C 100°C - 1066°C 100°C - 1066°C

Operating Temp.
Range
Intermittent 1066°C - 1200°C 1066°C - 1200°C 1066°C - 1200°C 1066°C - 1200°C

Note
-26 models supplied with European
type cord and plug. All other models
not supplied with cord and plug.

6
 Unpacking

Unpacking
Unpack furnace from box. The owners manual
and door handle are included in the box. After
unpacking the furnace, attach the door handle
and remove packing material from inside
furnace chamber. The furnace is supplied with
one hearth plate. The Type 1500 furnaces do
not come with a power cord because
current requirements are too great to be
handled by ordinary power cords and
standard wall supply. (Exception: the -26
European models are supplied with a power
cord.)

7
Installation
Caution
Be sure ambient temperature
does not exceed 104°F (40°C);
ambients above this level may
result in damage to the control-
ler. Allow at least six inches of
space between the furnace and
any combustible surface. This
permits the heat from the fur-
nace case to escape so as not
to create a possible fire hazard.
For supply connections, use 14
AW or larger wires suitable for at
least 392°F (200°C).
Note
(-26) models are supplied with a
European cord set.
Warning
To avoid electrical shock, this
furnace must be installed by a
competent electrician who
ensures compatibility among
furnace specification, power
source and ground code
requirements.
8
Installation
Site Selection
Install furnace on a sturdy surface and allow
space for ventilation.
The electrical specifications are located on the
specification plate on the back of the furnace.
Consult Barnstead/Thermolyne if your electrical
service is different than those listed on the
specification plate. Prior to connecting your Type
1500 furnace to your electrical supply, be sure the
two position power switch is in the OFF position.
Your 1500 furnace may be wired either directly
through a conduit system or by using a power
cord and plug which conforms to the National
Electrical Codes and electrical code requirements
of your area. The terminal block to be used in
wiring is located on the lower rear of the furnace.
(See Figure 1, page 29 for wiring locations.)
Warning
Do not use in the presence of
flammable or combustible chemi-
cals. Fire or explosion may result;
this device contains components
which may ignite such materials.
Hot Surface
To avoid burns, do not touch the
interior or exterior surfaces of the
furnace during use or for a period
of time after use.
 Single Setpoint Temperature
Control (Automatic Operation)
Note
The temperature control in these
models is a single set-point device.
By using the UP or DOWN buttons,
a specific
temperature can be chosen. The
control will cause the furnace cham-
ber to heat to the chosen tempera-
ture and hold it at this temperature
until you turn off the power switch or
select another temperature.
Warning
To avoid electrical shock, this fur-
nace must have the door switch
connected and operating properly. If
the furnace power
light does not go out while t
he door is open, consult the
Troubleshooting section
before proceeding.
Note
When performing the operations with
the controller, remember that if more
than eight to ten seconds elapse
before the buttons are used again,
the display screen will automatically
switch back to displaying chamber
temperature.
If this happens, light up the front
panel again and step through each
parameter until you reach the point at
which the interruption occurred. The
parameter values you adjusted
earlier will not be lost or altered.
Holding down the SCROLL button
allows longer viewing time.
Single Setpoint Temperature
Control (Automatic) Operation
(Models FD1530M, FD1530M-26, FD1534M,
FD1535M, FD1538M)
Controls and Displays
Power Switch:
Turn power switch to the “ON” position. The
CONTROLLER will illuminate when power is on.
Furnace Power Indicator:
The amber furnace power light will illuminate
whenever the door is closed. This light will go out
only when the door is open or when there is an
over-temperature condition.
Door Safety Switch:
The door safety switch removes power from the
heating elements when the door is opened. Open
and close the door a few times, note that the
amber furnace power light will go out while the
door is open. If the furnace power light does not
go out while the door is open, consult the
Troubleshooting section before proceeding.
Control Buttons
To illuminate the “DOWN” button, “SCROLL”
button, and “UP” button, touch anywhere on the
front panel.
Digital Readout:
The Digital Readout continuously displays
chamber (upper display) and setpoint (lower
display) temperatures unless the “SCROLL”
button is depressed.
9
SINGLE SETPOINT TEMPERATURE CONTROL (AUTOMATIC OPERATION)
Caution
Do not exceed limitations for
continuous or intermittent
operating temperature shown in
the General Specifications.
Exceeding these limits will result
in severely reduced heating
element life.
Note
If the power to furnace is turned
off or interrupted while in “tuning”
upon returning power to furnace,
the controller display will indicate
“LinE FAIL” because sampled
data could be questionable. To
restart tuning, refer to Tuning
procedure. If the controller cannot
maintain temperature set-point,
“TunE FAIL” will appear on
display. First, correct problem
responsible for not maintaining
the temperature setpoint, then
restart the “tuning” procedure.
10
Start-up Display:
When the power switch is turned on, the
controller will perform a self-test to make sure
controller is operating properly. (If all four 1’s do
not light up or fails to go to “8888” contact
Thermolyne.)
Adjusting Furnace Setpoint
Temperature
To illuminate the “DOWN” button, “SCROLL”
button, and “UP” button, touch anywhere on the
front panel.
Push the “UP” button or the “DOWN” button to
modify the temperature setpoint (lower digital
display).
Tuning
This control incorporates a self tuning feature
which determines the optimum control
parameters for the best temperature accuracy.
We recommend that you tune the furnace to your
specific application to obtain the best results.
Perform the following procedures when you first
set up your furnace and each time you change
your load type or operating temperature.
To tune your furnace
Load your furnace with a load characteristic of
those you intend to heat in it.
Set the furnace’s setpoint to the temperature you
intend to use for your application.
 SINGLE SETPOINT TEMPERATURE CONTROL (AUTOMATIC OPERATION)
Note
The controller is fitted with a
mechanical relay which is
de-energized in the alrm mode. This
relay, when de-energized, removes
power from the heating elements. If
the primary control circuit fails, the
OTP will control the furnace
temperature at the preset value you
have entered, it does not shut off
the furnace, but will maintain the
chamber temperature at that
value.
Push the “SCROLL” button until ‘TUNE”
appears. To start the tuning function, push the
“UP” button.
When the tuning process is started, the lower
display will flash ‘tunE” along with the furnace
temperature setpoint. During tuning, the
temperature setpoint cannot be changed. To
change temperature setpoint ‘tunE” must be
turned “OFF.” (To stop the tuning function,
push the “DOWN” button.)
Changing Temperature Indication
Push “SCROLL” button once, “°C” will appear.
This indicates temperature measurement.
(Contact Thermolyne if control needs to be
changed to °F.)
Setting the High Alarm Temperature
(Over Temperature Protection OTP):
Push “SCROLL” button until “AL.SP” (Alarm
Setpoint) appears. The lower display should
indicate 1100°C.
Depress either the “UP” or “DOWN” button to
select the OTP value you desire. Thermolyne
recommends that you set the value either at the
maximum operating temperature of the furnace
or a value of 20 degrees above your working
temperature if you desire to provide protection
for your work load.
11
Operation of 2 Ramp and 2
Dwell Programmable Models
Note
In the event of a thermocouple
break (open circuit), the numeric
display increases rapidly upscale,
then displays “Snb” (sensor
break) and may alternately flash
“HiAL” (high alarm) and/or dAL
(deviation alarm) and the sensor
break power value. A reversed
thermocouple connection or
incorrect thermocouple will cause
the display to read “ur” (under-
range) and the control will main-
tain the sensor break power
output value selected.
Note
When performing operations with
the controller, if you depress and
release either the “PAR,” scroll
“UP” or scroll “DOWN” buttons
and more than six seconds
elapse before the buttons are
used again, the display will auto-
matically switch to displaying
chamber temperature. If this
happens, you will have to step
through each parameter until you
reach the point at which the
interruption occurred. The
parameter Values adjusted earlier
will not be lost or altered. Holding
down on “PAR” allows longer
viewing time.
12
Operation of 2 Ramp and 2
Dwell Programmable Models
(Models FD1540M, FD1540M-26, FD1545M,
FD1544M, FD1548M)
Controls and Displays
Digital Readout:
The digital readout continuously displays
chamber (upper display) and setpoint (lower
display) temperatures unless the PAR
(parameter) button is depressed.
If a program is in either run, Hb or Hold, pressing
“PAR” once causes the lower display to indicate
the current segment of the program (r1, d1, r2,
d2, or Hb) along with °C or °F. If the program is
currently in either d1 and d2, the value shown
below these parameters (d1 and d2) reflects the
time remaining in the segment.
While the program is in run, Hold, or Hb, the set
point shown on the bottom display is the current
working set point.
When the controller is in idle, depressing PAR
shows each parameter and its current value in
turn on the display. The parameter value can
either be modified with the “up” or “down” push
buttons or left unmodified.
See Parameters for a list of the controller
parameters in order.
Power Switch:
Set power switch to the “ON” position. The
CONTROLLER will illuminate when power is on.
 OPERATION OF 2 RAMP AND 2 DWELL PROGRAMMABLE MODELS
Caution
Remember that whenever the
power switch is turned “ON”, the
furnace will begin to heat at the
setpoint temperature that was
previously set. This value will
remain unchanged for up to a
year without power being applied
to the control.
Warning
To avoid electrical shock, this
furnace must have the door
switch connected and
operating properly. If power light
does not go out while the door is
open, consult the Troubleshoot-
ing section before proceeding.
Note
Push button “A/M” and light “OP”
are inactive and not used.
Note
The controller is filled with a
mechanical relay which is de-
energized in the alarm mode.
This relay, when de-energized,
removes power from the heating
elements, If the primary control
circuit fails, the OTP will control
the furnace temperature at the
preset value you entered. It does
not shut off the furnace but will
maintain the chamber tempera-
ture at that value.
Furnace Power Indicator:
The amber furnace power light will illuminate
whenever the door is closed. This light will go
out only when the door is open or when there is
an over-temperature condition.
Door Safety Switch:
The door safety switch removes power from the
heating elements when the door is opened.
Open and close the door a few times, note that
the amber furnace power light will go out while
the door is open. If the furnace power light does
not go out while the door is open, consult the
Troubleshooting section before proceeding.
Parameters
PROG - program options . By pushing up or
down buttons, three options can be chosen: run
- to start program; idle - to end program; hold -
to hold program until further action.
SP - set point temperature. When running a
program, it is the last temperature value
attained. Push up or down button to set.
TUNE - self-tuning feature. Push up or down
button to set.
LC - loop count. The number of times the
program is repeated. Push up or down button
to set.
r1 - ramp rate #1. The rate of heat increase or
decrease in °/minute. Push up or down button
to set.
L1 - temp level #1. The temp level that r1 will
attain. Push up or down button to set.
d1 - dwell (soak) time #1. The amount of time
in minutes to hold L1 temp level #1. Push up or
down button to set.
r2 - ramp rate #2. The rate of heat increase or
decrease in °C/minute. Push up or down button
to set.
13
OPERATION OF 2 RAMP AND 2 DWELL PROGRAMMABLE MODELS
Note
All temperature dependent pa-
rameters are automatically con-
verted when the temperature unit
(C or F) is changed.
14
L2 - temp level #2. The temperature level r2 will
attain. Push up or down button to set.
d2 - dwell (soak) time #2. The amount of time in
minutes to hold L2 temperature level #2. Push up
or down button to set.
Hb - “holdback.” Automatically places the
programmer into “HOLD” if the measured value
deviates more than a specified amount from
programmer setpoint. When measured value
reenters the holdback band, the timing for the
segment resumes. (Parameter is expressed in °C
and only functions when running a program).
Push up or down button to set.
HiAL - high alarm (over temperature
protection). Push up or down button to set.
Thermolyne recommends that you set the value
either at the maximum operating temperature of
the furnace or a value of 20 degrees above your
working temperature if you desire to provide
protection for your work load.
The next three parameters - Proportional Band,
Integral and Derivatives - are the three control
parameters of a P.l.D. control system. These
parameters will be set when you tune your
furnace. (See Tuning.)
Proportional Band (Prop)
Integral Time (In.T)
Derivative Time (dEr.T)
HPl - High Power Limit (%) This parameter limits
the average maximum power that is applied to the
heating elements. Remember that this parameter
does not reduce the voltage to the elements. It
reduces the average power to the elements by
cycling power on and off.
C/F - Centigrade/Fahrenheit. Choose the
desired temperature unit by depressing the “UP”
or “DOWN” push-button.
OPERATION OF 2 RAMP AND 2 DWELL PROGRAMMABLE MODELS

Tuning Your Controller

This programmable control has an automatic
tuning feature which installs optimum tuning
parameters to give the best temperature
accuracy. No manual loading of tuning
parameters is needed. We highly recommend
using this feature to provide the best
temperature accuracy the controller can attain.
Perform the following procedures when you first
set up your furnace and each time you change
your load type, operating temperature, or
program.
To initiate the self tune feature
Load your furnace with a load characteristic of
those you intend to heat in it.

If you will be using the controller as a single

Setpoint Controller, set the furnace’s setpoint to
the temperature you intend to use for your
application.

If you will be running a multistep program, set

the furnace’s setpoint to the value of L1 (temp
level #1).

Push “PAR” button until TUNE is displayed,

then push “UP” or “DOWN” button to turn tune
“ON.”

During the operation, TUNE flashes in the

lower display. Do not make any adjustments to
the controller parameters during this period.
The self tuning is finished when TUNE no
longer flashes in the lower display.

Self tuning will calculate values for:

Proportional band (prop)
Integral time (Int.t)
Derivative time (der.t)

15
OPERATION OF 2 RAMP AND 2 DWELL PROGRAMMABLE MODELS
Caution
Do not exceed limitations for
continuous or intermittent operat-
ing temperature shown in the
General Specifications (in
furnace manual). Exceeding
these limits will result in severely
reduced heating element life.
16
• Self tuning cannot be initiated while running a
program.
• A power failure will cause the TUNE parameter
to revert back to NO. (Reset tune parameter to
YES).
• If there are alarm conditions during self tuning,
they flash alternately with TUNE.
Operating the Controller
Single Set Point Operation
The programmable control can be used as a
single setpoint control or as a programmable
control. To use as a single set point control simply
push up or down buttons to choose a specific
temperature. The control will cause the furnace
chamber to heat to the chosen temperature and
hold this temperature until the power switch is set
to OFF or another temperature is selected.
a. The setpoint temperature presently set
in the control will be read out on the
lower display.
b. To change this set point, depress the
“UP” or “DOWN” push button until the
desired setpoint value is displayed then
release the button.
c. At this point the furnace will begin to
heat if the new set point temperature you
have chosen is higher than the present
chamber temperature.
OPERATION OF 2 RAMP AND 2 DWELL PROGRAMMABLE MODELS

Programming Controller
To run a program, first determine your ramp
rate, dwell times. and program levels. It is
helpful to graph your program out for ease of
loading the program into controller.

A maximum of 2 ramp and 2 dwell segment

combinations are available, thus enabling 2
different set point levels to be achieved. Each
ramp is programmed by specifying the
temperature level (L1) and the required ramp
rate (r1). The programmer then automatically
calculates the time that is required to attain the
temperature level (L1) based on the desired
ramp rate (r1). Dwell segments (d1) then can
be attached to each temperature level (L1) to
hold that temperature for a specified amount of
time.

Make sure the PROG parameter is set to idle

(to stop program) when entering program
values. (See Parameters.)

Push “PAR” until “r1” is displayed. Push “UP” or

“DOWN” buttons and set ramp rate “r1” (heat
increase or decrease) in °C/minute.

Push “PAR” until “L1” is displayed. Push “UP”

or “DOWN” buttons and set temperature level
“L1.” This is the target temperature for the first
ramp.

Push “PAR” until “d1” is displayed. Push “UP”

or “DOWN” buttons and set dwell (soak) time
“d1” in minutes.

Push “PAR” until “r2” is displayed. Push “UP” or

“DOWN” buttons and set ramp rate “r2” in C/
minutes.

Push “PAR” until “L2” is displayed. Push “UP”

or “DOWN” buttons and set temperature level
“L2.” This is the target temperature for the
second ramp.
17
OPERATION OF 2 RAMP AND 2 DWELL PROGRAMMABLE MODELS

Push ‘PAR’’ until “d2” is displayed. Push “UP” or

“DOWN” buttons and set dwell (soak) time “d2” in
minutes.

Push “PAR” until “SP” is displayed. Push “UP” or

“DOWN” buttons and modify set point
temperature. After “d2” dwell time has expired,
thus ending the program, the last temperature
level to be attained will be equal to “SP”
temperature. For example, if after your program
has been completed, you want the furnace to cool
to ambient, set “SP” to 20. This will be the last
temperature level attained.

Push “PAR” until “LC” is displayed. Push “UP” or

“DOWN” buttons and set “LC” (loop count -
number of times program is repeated).

Skipping Segments
If you desire to skip a ramp or dwell segment,
follow this procedure:

• for a dwell segment, enter a setting of “0”

minutes.

• for a ramp segment, enter a high value such as

100°/min. This will cause controller to skip to next
segment as fast as the furnace is capable.

Setting the Holdback Feature

This controller features a holdback (Hb) function
to ensure programmed parameter values are
adhered to. Holdback is set in display units
(degrees C or F) and represents the allowable
excursion of measured value away from the
current set point, either above or below, before
the program is forced into hold (clock stops).
18
OPERATION OF 2 RAMP AND 2 DWELL PROGRAMMABLE MODELS

The program will remain in hold until the

measured value comes within holdback band
(clock starts). This feature is active the whole
time that the program is running. (Holdback
functions only while running a program).

Push PAR until “Hb” is displayed. Select

desired holdback setting - a setting of 20° is
recommended.

If a running program is forced into holdback,

the illuminated dot below the “R” symbol on
controller will flash and the PROG parameter
will indicate “Hb.” When the program is in
“holdback,” it effectively lengthens the time of
the program - if the holdback band “Hb” is set
too low, the program will never escape the
holdback band, thus the program will never be
completed. If you do not want to use the
holdback function, set “Hb” to an extremely
large value.

19
Implementing Programs
Note
Parameter values r1, L1, D1, r2,
L2, r2, D2 and Lc cannot be
adjusted while running a program.
20
Implementing Programs
When you have finished programming and are
ready to run your program, push “PAR” until
PROG is displayed. Pushing the “UP” or “DOWN”
buttons, you have three options: “Run” (to start
program), “idle” (to stop program), “hold” (to hold
program) - parameter values can be changed
when hold is chosen.
Program Execution
When “run” is selected, the program will start from
the actual furnace temperature at that point in
time. Also, the dot under “R” on the control will
illuminate to indicate the program is running.
Program Hold
To adjust parameters while running a program,
you must put control into “Hold.” Push “PAR” until
“prog” is displayed. Push “UP” or “DOWN”
buttons until Hold is displayed. When the dot
underneath “R” on controller flashes and “Hold” is
indicated at the “prog” parameter, the controller is
in Hold. Now you are able to adjust all
parameters. To restart the program, set “prog” to
“run” again.
Program Idle
To stop program, push “PAR” button until “prog”
is displayed. Push “UP” or “DOWN” buttons until
“idle” is displayed. This will terminate program.

Caution
Do not overload your furnace
chamber. If the load is to be
heated uniformly, it should not
occupy more than two-thirds of
any dimension of the chamber.
Failure to observe this caution
could result in damage to furnace
components.
Furnace Loading
Furnace Loading
For best results of furnace loading, use less
than two-thirds of any dimension of the
chamber. If you are heating a number of small
parts, spread them throughout the middle two-
thirds of the chamber.
• Keep objects away from thermocouple.
• Block up load with small pieces of ceramic, or
use the supplied hearth plate.
• Use insulated tongs and mittens when loading
and unloading furnace.
• Always wear safety glasses.
Use hearth plated supplied with furnace (Cat.
No. PHX2) to protect bottom heating element.
21
Preventative Maintenance
Warning
To avoid electrical shock, this
furnace must always be discon-
nected from the power supply
prior to maintenance and servic-
ing. Refer servicing to qualified
personnel.
22
Preventative Maintenance
Contamination is a major cause of element
failure, therefore, when possible, remove the
fume forming material before heating. (e.g.,
cleaning cutting oil from tool steel).
Housekeeping is vital to your electric furnace—
KEEP IT CLEAN! Run your furnace up to 1600°F
(870°C) empty occasionally to burn off the
contamination that may exist on the insulation
and elements. Run for approximately two hours
with the door slightly open.
Element life is reduced somewhat by repeated
heating and cooling. If the furnace is to be used
again within a few hours, it is best to keep it at the
operating temperature or at a reduced level such
as 500°F (260°C).
During normal use the thermocouple in your
furnace can become oxidized and cause
inaccurate control; therefore, we suggest that if
you regularly use your furnace you should check
your thermocouple once every six months to
assure the accuracy of your control.
 Troubleshooting

Troubleshooting
Warning The Troubleshooting section is intended to aid
Disconnect from power supply in defining and correcting possible service
before servicing. problems. When using the chart, select the
problem category that resembles the
malfunction. Then proceed to the possible
causes category and take necessary corrective
action.

Problem Possible Causes Corrective Action

The furnace is not connected to the Check furnace connection to

The power light does not power supply. power supply.
illuminate.
ON and OFF power switch defective. Replace power switch.

Problem Possible Causes Corrective Action

Replace thermocouple.
Oxidized or contaminated
thermocouple. Tighten connections.

Poor thermocouple connection. Use proper loading procedures.

Improper loading procedures. Clear area around furnace

base.
Poor ventilation of base.
Inaccurate temperature readout. Reconnect thermocouple
Thermocouple connections reversed. correctly.

Control out of calibration. Contact Barnstead/Thermolyne.

P.I.D. values invalid. Re-tune control.

Control malfuction. "EE FAIL" will be Verify and correct all parameter
displayed. (Single Set Point Control) and configuration values. If "EE
FAIL" persists, replace control.

23
TROUBLESHOOTING

Problem Possible Causes Corrective Action

Check power source and fuses

No power
or breakers.
Thermocouple is open or
Replace thermocouple or check
thermocouple leads reversed. "SnSr
thermocouple connections.
FAIL" will be displayed.
Verify and correct all
Single Set Point Controller
parameters and configuration
malfunction. "EE FAIL" will be
The furnace does not heat. values. If "EE FAIL" persists,
displayed.
replace control.
Element burned out. "LP.Br" will be
Replace muffle (element).
displayed. (Single Set Point Control)
Replace solid state relay.
Solid state relay defective.
Realign or replace door safety
Door switch malfunction.
switch.

Install line of sufficient size and

proper voltage. (Isolate furnace
Low line voltage.
from other electrical loads.)
Heavy load in chamber.
Lighten load in chamber to
Slow heat up.
allow heat to circulate.
Wrong heating in element.
Install proper element.
Low ramp rate setting.
Increase setting.

Clean up spills in chamber.

Ventilate chamber by leaving
Heating harmful materials. door cracked slightly open
when heating known harmful
Control unit malfunction. regents.

Incorrect element. Replace control unit.

Repeated element burnout.
Oxidized thermocouple leading to Install proper element.
inaccurate reading.
Replace thermocouple.
Wired improperly.
Check wiring diagram for
correct wiring of your furnace.

24
 Maintenance and Servicing

Maintenance and Servicing

Note
Perform only maintenance de-
To Replace A Heating Element:
scribed in this manual. Contact an
authorized dealer or our factory a) Disconnect furnace from power sup-
for parts and assistance. ply.

b) Remove back terminal cover (See

Figure 2, page 29.)

c) Loosen the nuts on the terminals of

the element to be replaced.

d) Straighten the leads of the old ele-

ment.

e) Open the door and pull the defective

element out. (It may be easiest to turn
the furnace so that the element to be
removed is on top.)

f) Slide the new element into place,

threading the leads through the insu-
lating porcelain bushing in the back of
the furnace.

g) Bend the elements across the “U”

shaped terminal clamp washer. Re-
place the adjacent element lead
across the washer. Put the round
terminal clamp washer over the ele-
ment leads and tighten the nut se-
curely. Cut off any excess lead wire.

h) Replace the back terminal cover.

i) Reconnect furnace to power supply.

25
MAINTENANCE AND SERVICING

To Replace The Platinel II Thermocouple:

a) Disconnect furnace from power supply.

b) Remove the back terminal cover (See

Figure 2, page 29.)

c) Remove old thermocouple by removing

T/C bracket and the washer and nuts on
the terminal posts. (Make sure small
bracket between the two metal pieces
does not fall out.)

d) Reassemble the bracket and plates

removed in step c to the new thermo-
couple and secure to furnace back plate.

e) Insert the new thermocouple into the

furnace until tip extends approximately
1" into the chamber. Make sure the T/C
lead wire with the colored beads is
connected to the terminal marked
positive. (See Figure 2, page 29.)

f) Secure thermocouple extension wires to

terminals (yellow to +).

g) Replace the back terminal cover.

h) Reconnect furnace to power supply.

To Replace Door Switch (Micro Switch):

a) Disconnect furnace from power supply.

b) Turn furnace upside down and remove

bottom plate.

c) Disconnect the wires from door switch.

Identify or mark wires disconnected
to insure proper placement and con-
nection when reinstalling.

26
 MAINTENANCE AND SERVICING

d) Remove two screws from door switch

and slide switch from the wire rod.

e) Insert new door switch while sliding it

over the wire rod. Secure door switch
to furnace.

f) Reconnect wires identified or marked

in Step (c) to new door switch.

g) Replace bottom cover.

h) Turn furnace upright and reconnect to

power supply.

i) Test operation of door switch.

To Realign Door Switch:

a) Disconnect furnace from power

supply.

b) Loosen set screw on cam and adjust it

so that the power is removed when
approximately a 15° movement is
made with the door handle. (When
opening the door.)

c) Tighten set screw on adjusting cam.

d) Reconnect furnace to power supply.

e) Test operation of door switch.

To Replace Temperature Control:

a) (Single Set Point Models) Simply

grasp control at top and bottom and
pull straight out.

27
MAINTENANCE AND SERVICING

b) (Programmable 2 Ramp & 2 Dwell

Control) Turn out retaining screw located
on right side of control and pull control
straight out.

28
 Figures

Figure 1 Figure 2

29
FIGURES

Figure 3
Single Set Point Controller

Figure 4
Programmable Control (2 ramp & 2 dwell)

30
Replacement Parts List

Part Number Description Model Number

FD1530M, FD1535M,
EL11X11 Heating Element, Top or Bottom FD1530M-26, FD1540M,
FD1545M, FD1540-26

FD1530M, FD1535M,
EL11X12 Heating Element, Sides FD1530M-26, FD1540M,
FD1545M, FD1540M-26

FD1538M, FD1534M,
EL11X15 Heating Element, Top or Bottom
FD1548M, FD1544M

FD1538M, FD1534M,
EL11X16 Heating Element, Sides
FD1548M, FD1544M

TC408X1A Platinel II Thermocouple All Models

RYX34 Solid State Relay All Models

FD1534,FD1535M,
RYX56 Mechanical Relay (120V)
FD1544M, FD1545M

FD1538M, FD1530M,
RYX57 Mechanical Relay (240 volt) FD1530M-26, FD1540M,
FD1548M, FD1540M-26

SWX78 Door Switch All Models

FD1530M, FD1535M,
CN71X51 Temperature Control, Single Set Point FD1538M, FD1534M,
FD1530M-26

FD1540M, FD1545M,
Temperature Control, Programmable
CN71X52 FD1540M-26, FD1548M,
(2 ramp & 2 dwell)
FD1544M

CR327X1 Cord Set FD1530M-26, FD1540M-26

SRX16 Strain Relief FD1530M-26, FD1540M-26

FD1534M, FD1535M,
SWX137 Power Switch (100-120 volt)
FD1544M, FD1545M

FD1538M, FD1530M,
SWX138 Power Switch (208-240 volt) FD1530M-26, FD1540M,
FD1548M, FD1540M-26

FD1534M, FD1535M,
PLX76 Cycle Light (100-120 volt)
FD1544M, FD1545M

FD1538M, FD1530M,
PLX82 Cycle Light (208-240 volt) FD1530M-26, FD1540M,
FD1548M, FD1540M-26

DR327X3A Door Only (Insulated) All Models

PHX2 Hearth Plate All Models

Door Assembly (includes handle and

DR327X4A All Models
hinge.)

PT327X4A Terminal Plate w/ Insulators All Models

31
Wiring Diagram

Ref. No. Description

CN1 Controller
DS1 Cycle Light
HR1 Heating Element
HR2 Heating Element
HR3 Heating Element
HR4 Heating Element
RY1 Relay, Mechanical
RY2 Relay, Solid State
S1 Switch, Power
S2 Switch, Door
TB1 Terminal Block
TC1 Thermocouple

Wiring Diagram - All Models

32
 Ordering Procedures

Please refer to the Specification Plate for the complete model number, serial number, and
series number when requesting service, replacement parts or in any correspondence
concerning this unit.

All parts listed herein may be ordered from the Barnstead Thermolyne dealer from whom
you purchased this unit or can be obtained promptly from the factory. When service or
replacement parts are needed we ask that you check first with your dealer. If the dealer
cannot handle your request, then contact our Customer Service Department at 319-556-
2241 or 800-553-0039.

Prior to returning any materials to Barnstead Thermolyne Corp., please contact our
Customer Service Department for a “Return Goods Authorization” number (RGA). Material
Returned without an RGA number will be returned.

33
34
35
36
37
Warning

Please note the following WARNINGS:

WARNING
This warning is presented for compliance with California Proposition 65 and other regula-
tory agencies and only applies to the insulation in this product. This product contains refrac-
tory ceramic, refractory ceramic fiber or fiberglass insulation, which can produce respirable
dust or fibers during disassembly. Dust or fibers can cause irritation and can aggravate pre-
existing respiratory diseases. Refractory ceramic and refractory ceramic fibers (after reach-
ing 1000°C) contain crystalline silica, which can cause lung damage (silicosis). The Interna-
tional Agency for Research on Cancer (IARC) has classified refractory ceramic fiber and
fiberglass as possibly carcinogenic (Group 2B), and crystalline silica as carcinogenic to
humans (Group 1).

The insulating materials can be located in the door, the hearth collar, in the chamber of the
product or under the hot plate top. Tests performed by the manufacturer indicate that there
is no risk of exposure to dust or respirable fibers resulting from operation of this product
under normal conditions. However, there may be a risk of exposure to respirable dust or
fibers when repairing or maintaining the insulating materials, or when otherwise disturbing
them in a manner which causes release of dust or fibers. By using proper handling proce-
dures and protective equipment you can work safely with these insulating materials and
minimize any exposure. Refer to the appropriate Material Safety Data Sheets (MSDS) for
information regarding proper handling and recommended protective equipment. For addi-
tional MSDS copies, or additional information concerning the handling of refractory ceramic
products, please contact the Customer Service Department at Barnstead|Thermolyne
Corporation at 1-800-553-0039.

38
 One Year Limited Warranty

Barnstead|Thermolyne Corporation warrants that if a product manufactured by

Barnstead|Thermolyne and sold by it within the continental United States or Canada
proves to be defective in material or construction, it will provide you, without charge, for a
period of ninety (90) days, the labor, and a period of one (1) year, the parts, necessary to
remedy any such defect. Outside the continental United States and Canada, the warranty
provides, for one (1) year, the parts necessary to remedy any such defect. The warranty
period shall commence either six (6) months following the date the product is sold by
Barnstead|Thermolyne or on the date it is purchased by the original retail consumer,
whichever date occurs first.
All warranty inspections and repairs must be performed by and parts obtained from
an authorized Barnstead|Thermolyne dealer or Barnstead|Thermolyne. Heating ele-
ments, however, because of their susceptibility to overheating and contamination, must be
returned to our factory, and if, upon inspection, it is concluded that failure is not due to
excessive high temperature or contamination, warranty replacement will be provided by
Barnstead|Thermolyne. The name of the authorized Barnstead|Thermolyne dealer
nearest you may be obtained by calling 1-800-446-6060 or writing to:
Barnstead|Thermolyne
P.O. Box 797
2555 Kerper Boulevard
Dubuque, IA 52004-0797
USA
FAX: (319) 556-0695
Barnstead|Thermolyne’s sole obligation with respect to its product shall be to
repair or (at its own discretion) replace the product. Under no circumstances shall it be
liable for incidental or consequential damage.
THE WARRANTY STATED HEREIN IS THE SOLE WARRANTY APPLICABLE TO
Barnstead|Thermolyne PRODUCTS. Barnstead|Thermolyne EXPRESSLY DISCLAIMS
ANY AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WAR-
RANTIES OF MERCHANTABILITY OR FITNESS FOR USE.

39
 Barnstead|Thermolyne
2555 Kerper Blvd. ISO
P.O. Box 797
Dubuque, IA 52004-2241
9001
REGISTERED
Phone: 319-556-2241 800-553-0039
Fax: 319-589-0516
E-Mail Address: mkt@barnstead.com

40